Method of manufacturing building material from volcanic magma

ABSTRACT

A method of manufacturing a building material includes the steps of directing molten volcanic magma from an underwater volcanic magna vent to a level above seal level via a tube formed from the magma, directing the molten volcanic magma into a mold located on a floating barge or located on land, and cooling the magma in the mold to form a building material. As an alternative to obtaining the magma from an underwater vent, the molten volcanic magma can be obtained from a vent on land, a lava pool or stream, tapping a lava tube, or the like. The molten volcanic magma can be cast, molded, formed, extruded, flossed, stranded, foamed and used as a heat source to produce harbor works, floors, walls, roofs, pipe, flotation, barges, vessels, insulation, fiber reinforcing and electricity.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of application Ser. No.08/281,520 filed on Jul. 28, 1994, now U.S. Pat. No. 6,149,855.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO A MICROFICHE APPENDIX

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention pertains generally to building materials and theirmethod of manufacture, and more particularly to using flowing volcanicmagma to make structures and material that is ordinarily made of wood,brick, stone, steel, concrete, glass and other materials, as well as togenerate electricity.

2. Description of the Background Art

In the past, structures have been made of wood, brick, stone, concrete,steel glass, plastic and other materials. Electricity has been generatedby the use of geothermal, sun, nuclear and fossil fuel heat sources.Flowing volcanic magma is not known to have been used to producebuilding materials or electricity.

The main disadvantage of the prior materials and heat sources is thehigh cost to produce the raw materials, the refining costs plustransportation to manufacturing site. Geothermal heat depletes, the sundoesn't always shine, and nuclear plants have a special safetyrequirement cost.

Volcanic magma has been flowing almost continuously somewhere in theworld from earliest times and will continue to do so for millennia tocome. It is uncontrollable: nothing can stop it from erupting throughthe earth's surface. It has been useless at best and terriblydestructive to life and property at its worst.

Therefore, there is a need for a method to tap flowing volcanic magma atlow cost and to utilize this natural resource to produce many things,including electricity. The present invention satisfies that need, aswell as others.

SUMMARY OF THE INVENTION

In accordance with the present invention, flowing volcanic magma isdirected into molds or machinery in the fluid state to produce barges,wharves, breakwaters, fences, sound barriers, road paving, pipe, floors,walls, roofs, building block, structural foam, batt insulation,insulating board and fiber strand reinforcement for plastics, as well asused as a heat source for the generation of electricity.

By way of example, and not of limitation, a building material ismanufactured in accordance with the present invention by directingmolten volcanic magma from an underwater volcanic magma vent to a levelabove sea level via a tube formed from the magma, directing the moltenvolcanic magma into a mold, cooling the magma in the mold to form abuilding material. In either case, the delivery tube is created bydirecting the flow of magma radially from a point of exit from saidmagma vent. This tube, which is formed of magma and can be perpendicularto the sea floor or extend at some other angle, can then be used tofurther direct the flow to the mold. Alternatively, the molten volcanicmagma can be obtained from a magma vent on land, such as by tapping alava tube or obtaining the volcanic magma from a lava pool or stream.The mold can be located on a floating barge, such as out in the sea, orbe located on land such as in a magma casting facility configured formanufacturing the building materials. The molten volcanic magma can bepoured into the mold and cooled at that point, or first compressed intothe mold if desired. While the building material could be left in themold and utilized, preferably the mold and building material areseparated by, for example, stripping the mold away from the buildingmaterial or otherwise removing the building material from the mold.

A main advantage of this invention is that many products can now be madewith little or no material cost.

Another advantage of this invention is that magma is stronger and moreresistant to chemical attack than concrete.

An important advantage of this invention is that it can be used togenerate electricity at very low cost.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more fully understood by reference to thefollowing drawings which are for illustrative purposes only, and wherelike reference numbers denote like parts:

FIG. 1 is a cross-sectional view of a magma casting facility accordingto the present invention.

FIG. 2 shows a perspective view of a dwelling constructed of precastparts made in the casting facility shown in FIG. 1.

FIG. 3 and FIG. 4 show cross-sectional views of the joints andfastenings in the dwelling shown in FIG. 2.

FIGS. 5 through 8 show a sequence in cross-section of a bargeconstruction method according to the invention.

FIG. 9 is a cross-sectional view showing a method of building a giantlava chimney over an underwater vent according to the invention.

FIG. 10 shows in cross-section an underwater generator according to theinvention.

FIG. 11 shows views of a flowing volcanic magma heated vertical boileraccording to the invention.

FIG. 12 is a cross-section of the flowing volcanic magma heated verticalboiler shown in FIG. 11 taken through line 12—12.

FIG. 13 schematically shows a volcanic magma being obtained from a lavatube originating from a surface vent.

FIG. 14 schematically depicts a pool and stream of molten lava as thesource of molten lava for use in the present invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

FIG. 1 shows a flowing volcanic magma casting facility in cross-section.In general, any type of machinery that can process glass can be used toprocess magma. Flowing volcanic magma is gated down an insulateddelivery tube 21 to trough 22 which is continuous along the top cornerof ganged, inclined slab molds 23. By way of example, and not oflimitation, the source of the molten volcanic magna can be a vent thatis located underwater or a vent that is located on land. Where anunderwater vent is the source, the molten volcanic magma can be broughtto a level above sea level via a tube formed from the magma before beingdirected into a mold. When a land vent is the source, a delivery tubecan be coupled into a cap on a surface vent, or a lava tube or the likecould be tapped. For example, a lava tube from Kilauea, which is one ofonly a few usable land sources of flowing magma, can be tapped as itdescends over a cliff and into the ocean. Kilauea is preferred sincemagma flows approximately sixty percent of the time. It will also beappreciated that the molten volcanic magma could be obtained from a lavapool or stream, either by dipping or piping, and directed into a mold.

Molds 23 have water filled, hollow steel spacers between the faces ofthe slabs (not shown) to keep the steel from getting too hot andgenerate steam for additional use at the same time. Overhead travelingcrane 24 inserts reinforcing and/or shuttering; helps close the molds;helps direct delivery tube 21; opens molds and removes the precast unitsto storage.

FIG. 2 shows a perspective view of a dwelling constructed of precastpanels made in the casting facility FIG. 1. It is assembled from fourfloor slabs 25; five wall slabs 26, one beam 27 and eight roof slabs 28.They are bolted at the joints as shown in FIGS. 3 and 4.

FIG. 5 shows a cross section of a floating mold 29 that defines the deck30, sides 31 and ends (not shown) that is being filled with flowingvolcanic magma. Reference number 32 indicates bulkheads (longitudinaland transverse).

FIG. 6 shows a cross-sectional view of the part 33 just cast in FIG. 5.It is supported by trapped air.

FIG. 7 shows a cross-sectional view of a drydock 34 supporting part 33by the deck overhang so that its skirts are above the floor of thedrydock 34 and will be engaged by the closing pour.

FIG. 8 shows the completed barge 35 floated out of the drydock 34.

FIG. 9 is a cross-sectional view showing a method of building a giantlava tube to the ocean surface and above from an underwater flowingvolcanic magma vent. A steel slip form cap assembly 48 is lowered overthe flowing volcanic magma vent 49. The diameter of 48 is a function ofthe flowing volcanic magma flow rate and cooling rate. The flowingvolcanic magma raises the cap and solidifies inside the perimeter whereit is cold. The direction of growth can be changed by pulling up andsideways on riser 50 by use of the cable 52, its winch 53 and usingthrusters or anchors on vessel 54. Flotation chamber 51 also helps holdthe assembly upright.

When the lava tube has risen well above sea level, magma can be directedinto molds and otherwise processed in various barges surrounding themagma chimney island. The molds can also be located on land, rather thanon barges, such as in a magma casting facility.

FIG. 10 shows in cross-section, an underwater generator system. Volcanicmagma is flowing from an underwater vent 36. A coaxial boiler tube 37 isinserted into the magma. A propeller 38, driven by the turbine 41 aidscirculation of the boiler water. Just above the steam chest 39 is acollar 40 to limit penetration of the probe. The steam turbine 41 drivesthe generator 42 and the feed water trap 43 collects the condensate fromthe condenser 44. A cable 45 and winch 46 on vessel 47 position theunderwater generator. Power cables (not shown) could go ashoreunderwater.

FIG. 11 and FIG. 12 show in cross-section a flowing volcanic magmaheated vertical boiler that could be especially efficient where a goodvertical drop is possible in the magma flow. Flowing volcanic magmaenters at lava tube 52 and flows across and down through a grate ofboiler header tubes 53 that are slightly larger in diameter andtherefore closer together than the vertical boiler tubes 55. Solids thatcannot pass the grate 53 as well as excess magma flow will be forcedthrough gate 54. Boiler sides 56 can move in or out to help control flowand to allow access to the tubes. Circulation of water and steam to thesteam chest 57 and heat transfer will be enhanced because this is acounter flow heat exchanger.

FIG. 13 schematically depicts an example of molten lava being obtainedfrom a volcanic vent 58 located on land 60. It will be appreciated thatvent 58 is any opening onto the land through which molten volcanic magmaflows, and that molten volcanic lava will typically flow downhill onceit exits the vent. In the example shown in FIG. 13, a lava tube 62follows the contour of land and eventually descends over a cliff 64above the ocean 66. Lava tube 62 can be tapped with a delivery tube 68of the type previously described herein to direct the molten lava into amold, or vent 58 can be capped or otherwise tapped in the manner shownand described with reference to FIG. 9 and obtaining molten lava from anunderwater vent. Referring also to FIG. 14, it will be appreciated thatthe molten volcanic magma also could be obtained from a lava pool 70 orstream 72, either by dipping, piping or the like, and directed into amold.

Accordingly, it can be seen that the present invention is directed toharnessing and using flowing volcanic magma in ways that have not beenused before. Molten volcanic magma is directed from an underwatervolcanic magma vent to a level above sea level via a tube formed fromthe magma, and into a mold located on a floating barge or on land, wherethe molten magma is cooled to form a building material. Alternatively,molten volcanic magma from a land vent is directed into a mold. On land,the molten volcanic magma can be obtained by tapping a lava tube,capping a vent and piping the magma, dipping into a lava pool or stream,piping the magma from a lava pool or stream, or the like. The object ofthe invention is to tap into or otherwise harness flowing volcanic magmafrom a natural source. No such use of volcanic magma has heretofore beenmade.

Although the description above contains many specificities, these shouldnot be construed as limiting the scope of the invention but as merelyproviding illustrations of some of the presently preferred embodimentsof this invention. Thus the scope of this invention should be determinedby the appended claims and their legal equivalents. Therefore, it willbe appreciated that the scope of the present invention fully encompassesother embodiments which may become obvious to those skilled in the art,and that the scope of the present invention is accordingly to be limitedby nothing other than the appended claims, in which reference to anelement in the singular is not intended to mean “one and only one”unless explicitly so stated, but rather “one or more.” All structural,chemical, and functional equivalents to the elements of theabove-described preferred embodiment that are known to those of ordinaryskill in the art are expressly incorporated herein by reference and areintended to be encompassed by the present claims. Moreover, it is notnecessary for a device or method to address each and every problemsought to be solved by the present invention, for it to be encompassedby the present claims. Furthermore, no element, component, or methodstep in the present disclosure is intended to be dedicated to the publicregardless of whether the element, component, or method step isexplicitly recited in the claims. No claim element herein is to beconstrued under the provisions of 35 U.S.C. 112, sixth paragraph, unlessthe element is expressly recited using the phrase “means for.”

What is claimed is:
 1. A method of manufacturing a building material,comprising: directing molten volcanic magma from a volcanic magma ventlocated on land and into a mold; compressing the magma into the mold;and cooling the magma in the mold to form a building material.
 2. Amethod as recited in claim 1, further comprising removing the buildingmaterial from the mold.
 3. A method as recited in claim 1, wherein themold in located on a floating barge.
 4. A method of manufacturing abuilding material, comprising: directing molten volcanic magma from avolcanic magma vent located on land and into a mold located on afloating barge; and cooling the magma in the mold to form a buildingmaterial.
 5. A method as recited in claim 4, further comprising removingthe building material from the mold.
 6. A method as recited in claim 4,further comprising compressing the magma into the mold.
 7. A method ofmanufacturing a building material, comprising: directing molten volcanicmagma from a volcanic magma vent located on land and into a mold:compressing the magma into the mold; cooling the magma in the mold toform a building material; and removing the building material from themold.
 8. A method as recited in claim 7, wherein the mold in located ona floating barge.
 9. A method of manufacturing a building material,comprising: directing molten volcanic magma from a volcanic magma ventlocated on land and into a mold located on a floating barge; cooling themagma in the mold to form a building material; and the building materialfrom the mold.
 10. A method as recited in claim 9, further comprisingcompressing the magma into the mold.